Hotstart OSE User manual

216300-000 rev5
OSE
INSTALLATION & OPERATION MANUAL
OIL CIRCULATING HEATING SYSTEM
FOR HAZARDOUS LOCATIONS

II installation & operation manual | ose heating system
(this page intentionally left blank)

installation & operation manual | ose heating system
IDENTIFYING YOUR SYSTEM
The HOTSTART heating system is designed to heat uids for use in marine propulsion, diesel-powered generator sets,
locomotives, gas compression or any large-engine applications. The system is pre-wired, pre-plumbed and assembled on
steel plate. Each heating system has an identication plate which includes the part number and serial number.
When ordering replacement parts, be sure to reference your heating system’s model number
and serial number found on the identication plate and following label:
WARRANTY INFORMATION
Warranty information can be found at www.hotstart.com or by contacting our customer service department at
[phone]. Have your model number and serial number ready when contacting the warranty department.
COPYRIGHT
Hotstart Manufacturing, Inc. is the owner of all trademarks and copyrightable material contained herein; all rights are
reserved; no form of reproduction is authorized without prior written consent from Hotstart Manufacturing, Inc.
NOTE: Typical heating
system
identication
plate. Your
identication
plate may vary.
Corporate &
Manufacturing
Headquarters
5723 E. Alki Ave.
Spokane, WA 99212 USA
509.536.8660
[email protected]
Oil & Gas Ofce
21732 Provincial Blvd.
Suite 170
Katy, TX 77450 USA
281.600.3700
[email protected]
Railroad Ofce
8915 Broadway
Merrillville, IN 46410 USA
219.648.2448
[email protected]
Europe Ofce
HOTSTART Europe GmbH
Hansestraße 79
51149 Köln, Germany
+49.2203.98137.30
[email protected]
Asia Pacic Ofce
HOTSTART Asia Pacic Ltd.
2-27-15-4F Honkomagome
Bunkyo-ku, Tokyo
113-0021, Japan
+81.3.6902.0551
[email protected]
IOM216300-000

II installation & operation manual | ose heating system
IMPORTANT SAFETY
INFORMATION
DANGER
!
Hazardous voltage: Before wiring, servicing or cleaning
the heating system, turn off the power and follow your
organization’s lockout and tagout procedure. Failure to do
so could allow others to turn on the power unexpectedly,
resulting in harmful or fatal electrical shock.
Combustion hazard: To prevent ignition of ammable
or combustible atmospheres, disconnect power before
servicing.
WARNING
!
Risk of ignition: To reduce the risk of ignition in hazardous
atmospheres, disconnect the equipment from the supply
circuit before opening system enclosures. Keep enclosures
tightly closed when in operation.
Sealing ttings: To reduce the risk of ignition in hazardous
atmospheres, conduit runs must have a sealing tting
connected within 18 inches (46 cm) of system enclosure.
WARNING
!
Electrical hazard: All electrical work must be done by
qualied personnel in accordance with national, state
and local codes.
CAUTION
!
Read instructions carefully: The safety of any system
incorporating this equipment is the responsibility
of the assembler. The safe and proper use of this
equipment is dependent upon the installer following
sound engineering practices. If the equipment is
used in a manner not specied by the manufacturer,
the protection provided by the equipment may be
impaired. All applicable electrical safety standards
dened by local jurisdictions must be followed.
(Reference EU directive 2014/34/EU in EU countries.)
• Read carefully: Installers and operators of this
equipment must be thoroughly familiar with the
instructions in this manual before commencing work.
• Hot surfaces: Avoid contact with the system while it
is in service. Some surfaces may remain hot even if
the system is not energized.
• Proper lifting: Use proper lifting equipment and
rigging to move this equipment. Create a plan
before attempting to move. Proper lifting locations
are identied with labels on each system; use these
locations when lifting and mounting the system.
• Rotating equipment: The heating system can start
automatically and without warning. Avoid contact
unless a lockout at the service panel has been
installed.
• Grounding: The heating system must be connected
to a suitable ground (protective earthing conductor).
• Overcurrent limiting: The power supply must be
protected by a suitable overcurrent limiting device.
• Power disconnection: A means to disconnect the
heating system from the power supply is required.
HOTSTART recommends that a power switch or
circuit breaker be located near the heating system
for safety and ease of use. Suitable branch circuit
protection shall be installed in accordance with
Article 430 Part IV of the NEC.
• Flameproof joints: Flameproof joints are not
intended to be repaired in the eld. Do not attempt
to repair any ameproof joints that become
damaged.
• Bend radius: Do not adjust cable bend radius in the
eld. Cables are pre-wired to meet the minimum
requirements for bend radius. If a cable is moved
from factory positioning, adjust cable to ensure
minimum bend radius met. For MC-HL cable,
minimum bend radius is 7 × (Ø) outer diameter
of the cable. For TC-ER-HL cable, minimum bend
radius is 4 × (Ø) outer diameter
CERTIFICATIONS
Max/ Min. process uid temp. 0 °C to 80 °C
Ambient temp. -20 °C to 40 °C
Voltages 120 to 575 V AC, 50/60 Hz,1/3 phase
Certications:
• Class I Div 1 Group D T3
• Class I Zone 1 Group IIA T3
Some models:
• Class I Div 2 Group D T3
• Class I Zone 2 Group IIA T3

III
installation & operation manual | ose heating system
TABLE OF CONTENTS
1 OVERVIEW | 1
1.1 HEATING SYSTEM COMPONENTS | 1
1.2 OPERATION OVERVIEW | 2
2 INSTALLATION | 3
2.1 OIL PLUMBING INSTALLATION | 4
2.1.1 OIL SUPPLY | 4
2.1.2 OIL RETURN | 4
2.2 OIL PLUMBING ILLUSTRATION
(COMPRESSOR) | 5
2.3 OIL PLUMBING ILLUSTRATION
(ENGINE) | 6
2.4 MOUNTING | 7
2.4.1 Tank and Pump | 7
2.5 ELECTRICAL CONNECTIONS | 7
2.5.1 Main Power Supply | 7
2.5.2 Customer Interface Connections | 8
2.5.3 MOTOR ROTATION CHECK | 9
3 COMPONENTS AND OPERATION | 9
3.1 SYSTEM COMPONENTS | 9
3.1.1 Pressure Relief Valve | 9
3.1.2 Control TCR (Temperature Control Relay) | 9
3.1.3 High-Limit TCR (Temperature Control Relay) | 10
3.2 INTERFACE COMPONENTS | 10
3.2.1 Prime Button | 10
3.2.2 Local/Off/Remote Switch | 10
3.2.3 Reset button/Motor Protection Switch
(MPS) | 10
3.2.4 Pressure Gauge | 10
3.3 HEATING SYSTEM START-UP | 10
3.3.1 First Run Procedure | 10
4 MAINTENANCE, REPAIR AND
TROUBLESHOOTING | 11
4.1 SYSTEM FAULTS | 11
4.1.1 Oil Faults | 11
4.2 SYSTEM MAINTENANCE | 11
4.2.1 Plumbing Connections | 11
4.2.2 Electrical Connections | 11
4.2.3 System Mounting | 11
4.2.4 Magnetic Contactors | 11
4.2.5 Pump Seal | 11
4.2.6 Pressure Relief Valve | 12
4.2.7 Pressure Gauge | 12
4.2.8 Volatile Corrosion Inhibitor (VCI) | 12
4.2.9 Temperature Control Relay | 13
4.3 RECOMMENDED MAINTENANCE | 14
4.4 STORAGE REQUIREMENTS | 14
4.5 TROUBLESHOOTING | 15

Iv installation & operation manual | ose heating system
(this page intentionally left blank)

1
installation & operation manual | ose heating system
1 OVERVIEW
WARNING
!
System location classication: Before installing the OSE heating system, ensure all system components are suitable for
the intended installation location by referring to the location classication labeling attached to the individual
system components.
1.1 HEATING SYSTEM COMPONENTS
NOTE: Component illustrations are for reference only and are not to scale. See part drawings for dimensions
and specications.
A. prime button
B. local/off/remote switch
C. reset button
D. Pressure/Temperature gauge
E. Pressure relief valve
F. Oil inlet
(0.5″ NPT)
G. Oil pump motor
H. Lift points
I. Oil outlet
(1.0″ NPT)
J. Heating element assembly
K. High-limit resistance
temperature device (RTD)
L. Identication plate
M. Heating tank
N. Control resistance
temperature device (RTD)
Figure 1. Typical OSE system
components. Model style and
conguration may vary. See part
drawings for dimensions and
specications.
A CB
D
HF GE
I
J
KL
NM

2installation & operation manual | ose heating system
1.2 OPERATION OVERVIEW
The OSE heating system is intended to maintain optimal oil temperature while the engine or compressor is shut down.
The heating system may be activated locally or by optional remote control (see SECTION 2.5.2). The OSE heating
system must be deactivated upon engine or compressor start-up.
During heating system operation, a rotary gear pump takes oil from the sump and forces it through the heating tank to the
oil return line. The oil pump will continuously circulate uid throughout the engine or compressor. To maintain consistent
uid temperature, the heating element will cycle on and off at the user-selected temperature control point.
An oil check valve (user-supplied and installed near the oil suction port) prevents backow while the engine or compressor
is operating. When the engine or compressor is shut down, the heating system should be activated locally or remotely to
resume maintaining the optimal oil temperature.
OIL SUPPLY
OIL RETURN
Figure 2. OSE system
operation. Component
illustrations are for
reference only and are not
to scale. See part drawings
for dimensions and
specications.

3
installation & operation manual | ose heating system
2 INSTALLATION
CAUTION
!
Pressure hazard: Power must be turned off and locked out at the service panel when the isolation valves are in the
closed position. Failure to do so may cause damage to heating system components, damage to lubrication oil, leaks
and unexpected release of heated oil.
Overheating hazard: After completing line installation, top off the uid levels to compensate for the uid used to ll
the lines and heating tank. Do not operate the heating system without the presence of uid. Position the heating tank
to ensure it is completely full of uid while in operation.
Pump priming: Fill supply line with uid. Pump is not self-priming. Fluid must be present in the pump before start-up.
Trapped air inside the pump will cause pump and seal damage.
Pump seal damage: Do not reduce the oil supply line to an inner diameter smaller than the pump inlet; pump seal
damage could occur.
Check valve: Hotstart recommends installing a customer-supplied swing-type or full-ow check (non-return) valve to
prevent oil from owing back into the oil sump. If the pump is installed above the minimum oil level, a check valve must
be installed.
Isolation valves: Hotstart recommends installing full-ow ball valves to isolate the heating system in order to perform
service on the system or engine without draining the oil.

4installation & operation manual | ose heating system
2.1 OIL PLUMBING INSTALLATION
2.1.1 OIL SUPPLY
Installing a short, straight oil supply line with a minimum
of ow restriction is the most important step toward
ensuring heating system longevity. When installing
the OSE oil supply line, refer to the following Hotstart
guidelines:
• Due to the increased viscosity of lubrication
oil, the oil supply line must be as short and
as straight as possible. Any 90° elbows will
reduce the maximum recommended oil
supply length. See Table 1 for Hotstart OSE
oil supply recommendations:
PUMP
INLET
HOSE INNER
DIAMETER
MAX. LINE
LENGTH
MAX. ELBOW
COUNT
1/2 inch
NPT
1 inch 20 feet
(6 meters)
4
NOTE: Each additional pair of 90° elbows will reduce
the maximum recommended line length
by ve feet (1.5 meters). To minimize ow
restriction, Hotstart recommends using
sweeping bends or 45° ttings.
• At a minimum, size the oil supply line per the
pump inlet. NOTICE! Do not reduce the
supply line inner diameter; pump seal
damage will occur.
NOTE: To maximize ow and allow the longest
possible supply line, install the largest
practical inner diameter hose; for most
installations, Hotstart recommends using a
hose with a size larger inner diameter than
the pump inlet.
• Install the oil suction port as low as possible
in the oil sump. NOTICE! Avoid installing
the oil suction port in a location that may
allow debris or sediment to enter the
heating system.
• Hotstart recommends installing a customer-
supplied, swing-type or full-ow check
(non-return) valve to prevent oil owing into
the sump. Install the check valve as close to
the oil supply port as possible.
• To ensure consistent oil heating, it is
acceptable to select a suction port on the
opposite side of the sump.
2.1.2 OIL RETURN
When installing the OSE oil return line, refer to the
following Hotstart guidelines:
• At a minimum, size the oil return line per the
pump outlet. NOTICE! Do not reduce the
return line inner diameter.
Depending on your application, there may be additional
requirements for locating the oil discharge port of the
Hotstart oil heating system:
hFor diesel engine applications, the oil return line
must be routed to the oil discharge port located at
opposite end of the oil sump. See SECTION 2.3.
hFor large-sized (four- or six-throw reciprocating)
compressor applications, the return line may be
routed to the opposite end of the oil sump or
the oil return line may be routed to a prelube
location. See SECTION 2.2.
hFor small- and medium-sized compressors, the
oil return line may be routed to the opposite
end of the oil sump or the return line may be
routed to a prelube location. See SECTION
2.2. If the return line is routed to a prelube
location, Hotstart requires installing a bypass to
the compressor oil sump, including a customer-
supplied tee tting and pressure relief valve.
Should ow become restricted due to low ambient
temperatures, the pressure relief valve along the
bypass line will open and allow heated oil to route
to the compressor’s oil sump. This alternate routing
will allow the heating system to maintain optimal
oil temperature while still providing the necessary
pressure to the prelube system. See Fig. 3.
NOTE: The pressure relief valve must be designated as
full-ow bypass and must be set for a maximum
of 65 psi. Hotstart does not recommend non-
code safety valves for this application.
Figure 3. Small compressor oil heating in lower ambient
temperatures (left). High oil viscosity restricts oil ow and increases
oil pressure. The pressure relief valve opens and allows oil to ow
directly to the sump in addition to the prelube location. In higher
temperatures, the bypass pressure relief valve is closed and oil is
routed directly to the prelube location (right).
Table 1. HOTSTART recommended hose inner diameters, line
lengths and elbow counts for OSE oil supply lines.

5
installation & operation manual | ose heating system
2.2 OIL PLUMBING ILLUSTRATION (COMPRESSOR)
TEE FITTING
SECTION 2.1.2
PRELUBE LOCATION
SECTION 2.1.2
OIL SUCTION PORT
SECTION 2.1.1
ISOLATION VALVES
OIL RETURN
SECTION 2.1.2
CHECK VALVE
SECTION 2.1.1
PRESSURE
RELIEF
VALVE
(UP TO 65 PSI)
SECTION
2.1.2
OIL DISCHARGE
PORT
SECTION 2.1.2
E-2E-1
V-2 V-3V-1
V-4
COMPONENT DESCRIPTION
V-1 USER SUPPLIED CHECK VALVE
V-2 USER SUPPLIED FULL FLOW ISOLATION VALVE
E-1 OIL PUMP
E-2 OIL HEATING ELEMENT
V-3 USER SUPPLIED FULL FLOW ISOLATION VALVE
V-4 OPTIONAL USER SUPPLIED PRV
OIL SUPPLY
SECTION 2.1.1

6installation & operation manual | ose heating system
2.3 OIL PLUMBING ILLUSTRATION (ENGINE)
OIL DISCHARGE PORT
SECTION 2.1.2
OIL SUCTION PORT
SECTION 2.1.1
OIL SUPPLY
SECTION 2.1.1
OIL RETURN
SECTION 2.1.2
E-2E-1
V-2 V-3V-1
COMPONENT
DESCRIPTION
V-1 USER SUPPLIED CHECK VALVE
V-2 USER SUPPLIED FULL FLOW ISOLATION VALVE
E-1 OIL PUMP
E-2 OIL HEATING ELEMENT
V-3 USER SUPPLIED FULL FLOW ISOLATION VALVE
CHECK VALVE
SECTION 2.1.1 ISOLATION VALVES

7
installation & operation manual | ose heating system
2.4 MOUNTING
CAUTION
!
Lifting hazard: Proper rigging and safety equipment
must be used to move this equipment. Do not lift the
heating system by any cords, electrical conduit or cabling.
Create a plan before attempting to move. Proper lifting
locations are identied on each system; use these
locations when lifting and mounting the system.
Overheating hazard: When mounting the heating tank,
position the tank so that it is completely full of oil while
in operation.
NOTICE
Heating system damage: Engine vibration will
damage the heating system; isolate the heating system
from vibration. Never mount the heating system or
components directly to the engine. If the heating
system is installed using rigid pipe, use a section of
exible hose to the supply and return ports to isolate
the heating system from engine vibration.
Improper mounting hazard: Reference heating
system component drawings before mounting the
system. Unless mounted properly, the heating system
will be unstable.
2.4.1 TANK AND PUMP
Mount the heater in a horizontal orientation with the
pump and pump motor above the tank. To ensure
that oil does not ow back into the sump, Hotstart
recommends mounting the heater at or below the
minimum oil level. If the pump is installed above the
minimum oil level, a check valve must be installed.
Reference drawings for mounting position. When
installing the heating tank, note that the tank requires a
minimum of 18 inches (46 cm) clearance to remove the
element for maintenance.
2.5 ELECTRICAL CONNECTIONS
WARNING
!
Hazardous voltage: Before wiring, servicing or cleaning
the heating system, turn off the power and follow your
organization’s lockout and tagout procedure. Failure
to do so could allow others to turn on the power
unexpectedly, resulting in harmful or fatal electrical
shock. Install in accordance with the National Electrical
Code (NEC) or Canadian Electrical Code (CEC), and any
applicable local codes (such as NFPA 496), based on the
installation location.
Electrical hazard: The heating system must be
connected to a suitable protective earthing conductor.
The heating system’s power supply must be connected
to a suitable overcurrent limiting device. A means of
disconnection from power supply is required. Hotstart
recommends that a power switch or circuit breaker be
located near the heating system for safety and ease of
use. Reference markings on heating system for specic
ratings.
Grounding conductor: Equipment grounding
conductors shall be sized per NEC 2017 Table 250.122
for US installations. For international installations, use
IEC 60079-0, Clause 16. Ground terminal block will
accept 16–4 AWG conductors. External grounding
connection not provided. Metallic conduit or armored
cable must be used.
2.5.1 MAIN POWER SUPPLY
1. Connect the specied power from the customer-
supplied circuit breaker to the terminal blocks
located in the main control box. See Fig. 6 on
following page.
NOTE: The specied power source must be within
plus or minus 10% of the rated voltage.
NOTE: The circuit breaker must be near the
heating system and easily accessible.
Hotstart recommends connecting the
heating system to a circuit breaker rated for
125% of the system’s maximum load.
Figure 4. Mount OSE unit in orientation shown. Do not mount at an
angle or in any other orientation.
Figure 5. OSE control box underside, showing 1.25 ″NPT
main power entrance (A) and 0.5 ″NPT customer interface wiring
entrance (B).
BA

8installation & operation manual | ose heating system
NOTE: The main power supply operates the
heating elements and the circulating
pumps. A transformer is used to operate
the control circuit. The transformer and
control circuits are overload-protected.
hFor three-phase applications, the terminal
blocks are labeled L1,L2 and L3 (A).
hFor single-phase applications, use the terminal
blocks labeled L1 and L2 or L and N (A).
2. Connect the main power ground wire to the ground
block (B).
2.5.2 CUSTOMER INTERFACE
CONNECTIONS
The following customer interface connections are
available for remote control and monitoring:
• TB2:1/TB2:2
Remote On/Off 24 V DC shutdown (C)
When activated, the remote on/off
connection shuts down the heating system.
When deactivated, normal heating will
resume. Use this connection for remote
operation of the heater when the local/
off/remote switch is turned to remote.
NOTE: The 24 V DC shutdown connection is
wired NC (normally closed) from the
factory; see system wiring schematic
for directions to switch to NO (normally
open) operation.
• TB2:3/TB2:4
Fault Signal (D)
The fault signal will indicate a heating system
shutdown, triggered by either the high-
limit temperature control relay or the motor
protection switch (see SECTION 4.1.1).
• TB2:5/TB2:6
Motor Run Signal (E)
A motor run signal indicates the pump motor
is running. If no signal is present, the pump
motor is not running.
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 1011 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
AB
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
E
D
C
Figure 6. Main power supply
and customer interface
connections as shown in the OSE
control box. Reference electrical
schematic drawing for proper
wiring locations; the following
illustrations are typical customer
interface locations.
A. Main power terminal block
B. Main power ground block
C. Remote On/Off 24VDC
shutdown
D.Fault signal
E. Motor run signal
12
3 4
SW1-B
X1:8P1:8
X1:9P1:9
P1:7X1:7
X1:7 X1:8
X1:9
TB2:3 TB2:4
TB2:5 TB2:6
TB2:1 TB2:2
1413
K2
K1
A1 A2
1211
K4
LOCAL SIGNAL
REMOTE SIGNAL
REMOTE ON/OFF 24 V DC
FAULT WHEN CLOSED
MOTOR ON WHEN CLOSED
Copper Wire Stranding Classes – Number of Strands
Wire
Size Torque Solid Class BClass CClass GClass HClass IClass K
2/0 AWG 120in· lbs 19 37
1/0 120in·lbs 19 37
1120in·lbs 19 37 ~133 ~259 ~210 ~836
2120in·lbs 719 ~49 ~133 ~161 ~665
4120in·lbs 719 ~49 ~133 ~105 ~420
6120in·lbs 719 ~49 ~133 ~63 ~266
840in·lbs 719 ~49 ~133 ~41 ~168
10 35in·lbs 1 7 19 ~27 ~104
12 35in·lbs 1 7 19 ~19 ~65
14 35in·lbs 1 7 19 ~19 ~41
Table 2. Line Side Wire Approvals. ~Quantity of strands for Classes
G, H, I, K may vary by manufacturer. Aluminum stranded wire range:
2/0 –#6 AWG. Minimum 90 °C wire for all electrical connections.

9
installation & operation manual | ose heating system
2.5.3 MOTOR ROTATION CHECK
Pump rotation (three-phase only): For three-phase
applications, check for proper pump rotation prior to
introducing uid to the pump. Reverse rotation while
the pump is lled with uid will cause pump seal failure.
Pump damage: Do not run the motor/pump assembly
dry for more than a few seconds. Running a motor/
pump for a prolonged period without being completely
lled with uid may cause damage to the pump seal.
The following procedures are for three-phase
applications only. Single-phase systems are prewired to
ensure the pump motor rotates in the correct direction.
1. With main power connected to the heating system
motor (see SECTION 2.5.1), energize the pump
while observing the rotation of the pump motor fan
at the rear of the motor. Refer to rotation decal on
motor for correct rotation.
hIf the pump motor does not rotate in the correct
direction, disconnect power and switch any two
electrical leads at the main power terminal block
(L1, L2, L3). Reconnect power. Repeat step 1 to
ensure motor rotates in the correct direction.
3 COMPONENTS AND
OPERATION
The following is an operational description for each of
the OSE interface and system components.
NOTE: Components installed in control box may
vary depending on the particular system
conguration purchased.
3.1 SYSTEM COMPONENTS
3.1.1 PRESSURE RELIEF VALVE
The oil pump pressure relief valve is internal to the
pump and releases pressure from the discharge side of
the pump to the suction side of the pump. No external
routing for discharge is required.
3.1.2 CONTROL TCR (TEMPERATURE
CONTROL RELAY)
The control TCR is used to control the temperature of the
Figure 7. OSE motor protection switch (left), showing stop/off (A)
and reset/on (B) buttons. To reset the MPS, the heating system must
be switched off and either the reset button or the MPS reset/on
button must be pressed.
OSE control TCR and high-limit TCR (above). The standard setting
for TCR1 control dial (C) is 104 °F (40 °C).
L1 L2
TB1
L3
L1 L2 L3
13
T1 T2 T3
13
MPS1
TB2
X1
2 4 6
1 3 5
7 8 9 10 11 12 13 14
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
CONTROL
0 100
A1 A3
T1 T2 T3
13 14 A2-
11 12
TCR1
HIGH
LIMIT
0 100
A
B
0 100
C

10 installation & operation manual | ose heating system
oil. The TCR uses a resistance temperature device (RTD)
to sense the oil temperature as the oil enters the heater.
The standard setting for the control temperature relay
(TCR1) is 104 °F (40 °C). See Fig. 7.
3.1.3 HIGH-LIMIT TCR (TEMPERATURE
CONTROL RELAY)
The high-limit TCR (TCR2) is a protection device to
prevent overheating of oil in the system. The high-limit
TCR uses an RTD located inside the element enclosure.
The default setting is 194 °F (90 °C) and should always
be at least 18 °F (10 °C) higher than the control TCR set
point. The high-limit TCR hysteresis is not used in the
high-limit control. See Fig. 7.
3.2 INTERFACE COMPONENTS
3.2.1 PRIME BUTTON
The prime button is used to remove remaining air in the
supply and return lines without energizing the heater
element.
3.2.2 LOCAL/OFF/REMOTE SWITCH
• local – The system is on.
• off – The system is off.
• remote – The system is turned on and
remotely controlled.
3.2.3 RESET BUTTON/MOTOR
PROTECTION SWITCH (MPS)
The motor protection switch (MPS) protects the pump
motor from overloads. The MPS will be set at the full load
amperage of the motor when shipped from the factory.
To reset the MPS, the local/off/remote switch must
be switched to off and the operator must press the
reset button. See SECTION 4.1.1.
3.2.4 PRESSURE GAUGE
The oil pressure gauge will indicate a pressure increase
when the pump motor is engaged by pressing the prime
button or during normal operation.
NOTE: Your system’s operating pressure may vary
depending on the conguration of the engine
or compressor.
3.3 HEATING SYSTEM START-UP
WARNING
!
Hazardous voltage: Before wiring, servicing or cleaning
the heating system, turn off the power and follow your
organization’s lockout and tagout procedure. Failure
to do so could allow others to turn on the power
unexpectedly, resulting in harmful or fatal electrical
shock.
NOTICE
Pump damage: Do not run the motor/pump assembly
dry for more than a few seconds. Running a pump that
is not completely lled with oil will cause damage to the
pump seal.
Proper heating operation: The high-limit temperature
control relay (TCR2) must be set at least 18 °F (10 °C)
higher than the control temperature control relay (TCR1)
for proper heating operation. This will prevent nuisance
tripping of the high-limit circuit.
3.3.1 FIRST RUN PROCEDURE
1. Check and tighten all electrical and plumbing
connections.
2. Ensure isolation valves are open before energizing
the system.
3. Press and hold the prime button to check the
pump for proper rotation. NOTICE! Do not run
the motor/pump assembly dry for more than
a few seconds. If you are operating a three-phase
heating system, check for proper rotation of the
pump motor when the system is energized. If the
pump motor is not rotating in the correct direction,
switch any two electrical leads at the main power
terminal block.
NOTE: Single-phase systems are prewired to
ensure the pump motor rotates in the
correct direction.
4. Bleed all trapped air from the heating system by
opening a plug or pipe tting at or near the pump.
Press and hold the prime button to evacuate any
remaining air in the lines.
NOTE: When priming the pump, the pressure
gauge should indicate an increase in
pressure. Your system’s operating pressure

11
installation & operation manual | ose heating system
may vary depending on the conguration
of the engine or compressor.
5. Turn the local/off/remote switch to local to
energize the heating system.
6. Once operation is satisfactory, turn the control dials
on the temperature control relay TCR1 to
the desired temperature setting. Hotstart
recommends a control temperature on TCR1 of
104 °F (40 °C). The high-limit temperature setting
on TCR2 should be set at 194 °F (90 °C). See
SECTION 3.1.2 and SECTION 3.1.3.
7. To verify that the 24 V DC customer controls
operate properly, turn the local/off/remote
switch to remote.
4 MAINTENANCE,
REPAIR AND
TROUBLESHOOTING
4.1 SYSTEM FAULTS
4.1.1 OIL FAULTS
If there is a failure in the system that causes a high
temperature to occur, the high-limit temperature
controller (TCR2) will shut down the entire heating
system, including the pump motor. The fault light will
illuminate. To restart the system, the local/off/
remote switch must be switched to off and then back
to either local or remote to resume operation.
A failure in the pump motor that causes the motor
protection switch to trip will shut down the entire system.
A fault signal will be transmitted. If this failure occurs,
the local/off/remote switch must be switched to
off and the operator must press the reset button
to reset the fault. For additional troubleshooting, see
SECTION 4.5.
4.2 SYSTEM MAINTENANCE
WARNING
!
Hazardous voltage: Before wiring, servicing or cleaning
the heating system, turn off the power and follow your
organization’s lockout and tagout procedure. Failure
to do so could allow others to turn on the power
unexpectedly, resulting in harmful or fatal electrical
shock.
Instructions for the following maintenance procedures
are provided to ensure trouble-free operation of your
heating system. Replacement parts must meet or exceed
original part requirements in order to maintain the
compliance level of the original heater.
NOTE: After maintenance is performed, refer to
SECTION 3.3 for system start-up procedures.
4.2.1 PLUMBING CONNECTIONS
Periodically check plumbing connections for leaks and,
if necessary, tighten connections. A loose connection on
the suction side will cause a loss of flow and cavitation in
the pump. It can also pull air into the heating tank and
cause an element failure.
4.2.2 ELECTRICAL CONNECTIONS
Vibration may cause terminals to loosen. At start-up,
tighten electrical connections. Check connections again
in a week. Tighten all electrical connections every three
months.
4.2.3 SYSTEM MOUNTING
Vibration may cause mounting bolts to loosen.
Periodically check and tighten all mounting bolts.
4.2.4 MAGNETIC CONTACTORS
Magnetic contactors are used as voltage switching
controls for motors and heating elements in Hotstart
heating systems. The contactors use 120 volt or 240
volt coils. To test for failure, check for continuity across
the coil connections; an open or direct-short reading
indicates a failed contactor coil.
The contacts on the magnetic contactor should be
inspected periodically for welding, arc erosion and
mechanical wear. If any of these conditions exist,
replace the magnetic contactor. Hotstart recommends
contactors be replaced every five years.
4.2.5 PUMP SEAL
Pump mechanical seals are controlled leakage devices
and are not intended to create a zero leak seal. Some
leaking from seal is expected during normal operation.
If seal becomes worn, replacement pump seals are
available.

12 installation & operation manual | ose heating system
NOTE: Instructions to replace the pump seals are
included with replacement seals.
4.2.6 PRESSURE RELIEF VALVE
The oil pump pressure relief valve is internal to the pump
and releases pressure from the discharge side of the
pump to the suction side of the pump. No maintenance
for this part is required.
4.2.7 PRESSURE GAUGE
The oil pressure gauge will indicate a pressure increase
when the pump motor is engaged by pressing the
prime button or during normal heater operation. No
maintenance for this part is required.
4.2.8 VOLATILE CORROSION
INHIBITOR (VCI)
A volatile corrosion inhibitor (VCI) is provided with each
control box and should be replaced once a year.

13
installation & operation manual | ose heating system
4.2.9 TEMPERATURE CONTROL RELAY
WARNING
!
Hazardous voltage: Before wiring, servicing or cleaning
the heating system, turn off the power and follow your
organization’s lockout and tagout procedure. Failure
to do so could allow others to turn on the power
unexpectedly, resulting in harmful or fatal electrical
shock.
If the OSE heating system does not maintain the desired
preset control temperature or signals a high-limit
temperature fault immediately upon system start-up,
the TCR (temperature control relay), the RTD (resistance
temperature device), or the RTD cable may require
replacement. To perform this troubleshooting, you
will need:
• Ohmmeter
1. De-energize the heating system. Verify uid
is present and ow is not restricted. Check
temperature gauge to ensure the liquid in the tank
is below 122 °F (50 °C).
2. Verify the control TCR (TCR1) is set correctly. Verify
that high-limit TCR (TCR2) is set at least 18 °F
(10 °C) higher than the control TCR set point. If the
measured resistance is between 80 and 120 ohms
continue troubleshooting. Proceed to step 3.
3. Using the ohmmeter, measure the resistance
between TCR terminals T1 and T2 (See Fig. 8):
hIf the measured resistance is between 80 and
120 ohms continue troubleshooting. Proceed to
step 4.
hIf the resistance is lower than 80 ohms or
higher than 120 ohms, contact Hotstart for
further assistance.
4. Using the ohmmeter, test for continuity between
TCR terminals T2 and T3:
hIf there is continuity between TCR terminals
T2 and T3, the TCR, RTD and RTD cable are
functioning correctly. Close control panel.
Allow uid to cool below high-limit preset
temperature. Perform system start-up (see
SECTION 3.3). If fault or temperature problems
persist after start-up, contact Hotstart for further
assistance.
hIf there is no continuity between TCR terminals
T2 and T3, locate connected RTD on the
heating tank. Unscrew the RTD plug from RTD.
5. Using the ohmmeter, touch the probes to RTD
pin 1 and pin 3. See Fig. 8. Note the resistance.
Touch the probes to RTD pin 1 and pin 4 to check
for continuity:
hIf the resistance between RTD pin 1 and
pin 3 is between 80 and 120 ohms and there
is continuity between RTD pin 1 and pin 4,
the RTD is functioning properly. Replace the
RTD cable.
hIf the resistance between RTD pin 1 and pin 3
is not between 80 and 120 ohms or there is
no continuity between pin 1 and pin 4, the
RTD is malfunctioning. Replace the RTD.
Figure 8. Control (TCR1) and
high-limit (TCR2) TCR showing
terminals T1, T2 and T3.
TCR TYPE RTD Position
TCR1 Oil Control 40 °C Oil Tank Inlet
TCR2 Oil High-limit 90 °C Oil Tank Outlet
Table 2. TCR types, default temperature settings and
corresponding RTD positions.
Figure 9. RTD leads and connectors shown on the RTD assembly,
TSX:WHT (A), TSX:RED (red wire) (B), TSX:RED (black wire) (C), and
Ground (D). Disconnect wire from connector as shown.
TS2:WHT
TS2:RED
TS2:RED
(W)
D
A
B
C

14 installation & operation manual | ose heating system
4.3 RECOMMENDED MAINTENANCE
INTERVAL MAINTENANCE TASK
At initial start-up Tighten electrical connections. See SECTION 3.3.
One week after initial start-up Check and tighten electrical connections. See
SECTION 4.2.2.
Every three months Tighten electrical connections.
Annually Drain, clean and ush heating system.
Check for cracked or weakened hoses and replace if
necessary.
Check electrical wiring and connections for wear and
excessive heat.
Check mounting bolts and tighten if necessary.
Every ve years Replace magnetic contactors. See
SECTION 4.2.4.
4.4 STORAGE REQUIREMENTS
If long-term storage is necessary, precautions must be
taken to ensure that the heating system is operational
for start-up. Steps must be taken to ensure that water
ingress is mitigated at all locations. All plugs and caps
must remain tight and a suitable cover must be provided
for the system. The cover must shield the system from
direct rain and protect from any directed spray that may
occur.
For any storage longer than three months, desiccant
bags must be placed next to the system if it is still in
the original packaging and inside the control box. If
the storage duration will be one year or longer, the
volatile corrosion inhibitor inside the control box must be
replaced at six month intervals.
New pump motors placed in long-term storage for a
year or longer may require relubrication before initial
use. If your pump motor has provisions for relubrication,
refer to the pump motor manufacturer’s relubrication
recommendations. Refer to the pump motor nameplate
for lubrication type.